Continuous flow rotary materials processing apparatus

Abstract

A continuous flow, rotary processing apparatus for horizontal transport of material at a predetermined rate. Material from an infeed conveyor enters a continuous system including at least one rotary drum operating about a horizontal axis. Each drum has a perforated circumferential wall with lateral lifters to induce flow and tumbling motion to the enclosed material. A flow control mechanism at the discharge end of each drum controls residence time of the material being processed. Material is fed and discharges from each drum through axial openings in which the flow control devices are mounted.

That which is claimed is: 
     
       1. A continuous flow, rotary processing apparatus for horizontal transport of material at a predetermined rate, comprising: a) a cylindrical enclosure, a central axis of which is oriented in a horizontal plane, said cylindrical enclosure being rotatable about said central axis, said cylindrical enclosure having a predetermined diameter and axial length, and further having first and second end walls, a cylindrical wall disposed between said first and second end walls, and at least one vane structure of a predetermined surface area disposed longitudinally on said enclosure cylindrical wall;   b) means to rotate said cylindrical enclosure at a constant predetermined rotational velocity;   c) means to allow ingress of material into said cylindrical enclosure, said ingress means being disposed in said first end wall;   d) an egress aperture disposed axially, with respect to said cylindrical enclosure, in said second end wall;   e) a hollow cylindrical chute disposed in said egress aperture and having a first open end extending into said cylindrical enclosure, and a second open end which is open to the exterior of said cylindrical enclosure; and   f) means to dislodge material resident in said cylindrical chute first end.   
     
     
       2. The continuous flow, rotary processing apparatus of claim 1, wherein said cylindrical chute has a predetermined length, and wherein said cylindrical chute extends inwardly into said cylindrical enclosure a predetermined distance. 
     
     
       3. The continuous flow, rotary processing apparatus of claim 1, wherein said cylindrical chute has a predetermined diameter. 
     
     
       4. The continuous flow, rotary processing apparatus of claim 1, wherein said cylindrical chute has a central axis, and wherein said chute central axis is angled upwardly between 1 and 70 degrees with respect to the horizontal plane of said cylindrical enclosure central axis. 
     
     
       5. The continuous flow, rotary processing apparatus of claim 1, wherein said cylindrical chute first end has a planar cross-sectional configuration which is angled between 0 and 90 degrees with respect to the horizontal plane of said cylindrical enclosure central axis. 
     
     
       6. The continuous flow, rotary processing apparatus of claim 1, wherein said cylindrical chute has a central axis, and wherein said chute central axis is angled upwardly between 1 and 70 degrees with respect to the horizontal plane of said cylindrical enclosure central axis, and wherein said cylindrical chute first end has a planar cross-sectional configuration which is angled between 0 to 90 degrees with respect to the horizontal plane of said cylindrical enclosure central axis. 
     
     
       7. The continuous flow, rotary processing apparatus of claim 1, wherein said cylindrical chute first end has a lip member disposed on a circular edge surface thereof, said lip member having a rounded surface and a predetermined cross-sectional diameter. 
     
     
       8. The continuous flow, rotary processing apparatus of claim 1, further comprising a housing structure, said cylindrical enclosure being a drum disposed within said housing structure, said cylindrical wall being constructed of a material which permits the passage of liquids and gases therethrough, said apparatus further comprising means, disposed inside said housing structure and outside said drum, to emit a liquid agent into said drum, whereby post consumer plastic waste material is input through said ingress means to said drum and is mixed with said liquid agent, said mixture being subsequently output through said egress aperture, via said cylindrical chute. 
     
     
       9. The continuous flow, rotary processing apparatus of claim 8, further comprising means to separate said liquid agent from the plastic waste material, said means to separate being disposed adjacent and axially in line with said egress aperture to receive said output mixture therefrom. 
     
     
       10. The continuous flow, rotary processing apparatus of claim 9, wherein said means to separate comprises a centrifugal liquid separation section disposed adjacent and axially in-line with said egress aperture and including a second cylindrical enclosure, second rotational means, second ingress means, a second egress aperture and second control means, said means to separate further comprising a dryer section disposed adjacent and axially in line with said second egress aperture and including a third cylindrical enclosure, third rotational means, third ingress means, a third egress aperture and a third control means. 
     
     
       11. The continuous flow, rotary processing apparatus of claim 10, wherein said apparatus further comprises means to meter plastic waste material of a predetermined size range to said ingress means, means to reduce said plastic waste material output by said third egress aperture to a second, smaller predetermined size range, and pneumatic means to transport plastic waste material from said size reduction means to a storage means. 
     
     
       12. The continuous flow, rotary processing apparatus of claim 10, wherein said means to rotate, said second rotational means and said third rotational means are communicatively connected to one another to synchronize the rotational velocities of said cylindrical enclosures. 
     
     
       13. The continuous flow, rotary processing apparatus of claim 10, further comprising means to clean and recycle said liquid agent, whereby said liquid agent is collected from an area below said drum and said second cylindrical enclosure, and is returned to said means to emit. 
     
     
       14. The continuous flow, rotary processing apparatus of claim 13, wherein said means to clean and recycle comprises means to extract particulate matter from said liquid agent and means to extract sedimentary matter from said liquid agent. 
     
     
       15. A continuous flow, rotary processing apparatus for horizontal transport of post consumer plastic waste material at a predetermined rate for use in a cleaning, drying and size reduction process, comprising: a) means to meter material of a predetermined size range;   b) a washing section, connected to said metering means, comprising: i) a cylindrical enclosure, a central axis of which is oriented in a horizontal plane, said cylindrical enclosure being rotatable about said central axis, said cylindrical enclosure having a predetermined diameter and axial length, and further having first and second end walls, a cylindrical wall disposed between said first and second end walls, and means, disposed on said cylindrical wall, to impart upward motion to material in said cylindrical enclosure;   ii) means to rotate said cylindrical enclosure;   iii) means to allow ingress of material from said metering meads into said cylindrical enclosure, said ingress means being disposed in said first end wall;   iv) an egress aperture disposed axially, with respect to said cylindrical enclosure, in said second end wall; and   v) means to control the rate of passage of material through said egress aperture;     c) a dewatering section, connected to said washing section, comprising: i) a second cylindrical enclosure, a central axis of which is oriented in a horizontal plane, said second cylindrical enclosure being rotatable about said central axis, said second cylindrical enclosure having a predetermined diameter and axial length, and further having first and second end walls, a second cylindrical wall disposed between said first and second end walls, and means, disposed on said second cylindrical wall, to impart upward motion to material in said second cylindrical enclosure;   ii) means to rotate said second cylindrical enclosure;   iii) means to allow ingress of material into said second cylindrical enclosure, said ingress means being disposed in said first end wall;   iv) a second egress aperture disposed axially, with respect to said second cylindrical enclosure, in said second end wall;   v) means to control the rate of passage of material through said second egress aperture; and     d) a drying section comprising: i) a third cylindrical enclosure, a central axis of which is oriented in a horizontal plane, said third cylindrical enclosure being rotatable about said central axis, said third cylindrical enclosure having a predetermined diameter and axial length, and further having first and second end walls, a third cylindrical wall disposed between said first and second end walls, and means, disposed on said third cylindrical wall, to impart upward motion to material in said third cylindrical enclosure;   ii) means to rotate said third cylindrical enclosure;   iii) means to allow ingress of material into said third cylindrical enclosure, said ingress means being disposed in said first end wall;   iv) a third egress aperture disposed axially, with respect to said third cylindrical enclosure, in said third end wall; and   v) means to control the rate of passage of material through said third egress aperture; and     e) output processing means connected to said third egress aperture.   
     
     
       16. A continuous flow, rotary processing apparatus for horizontal transport of material at a predetermined rate, comprising: a) a housing structure   a) a drum disposed within said housing structure, a central axis of which is oriented in a horizontal plane, said drum being rotatable about said central axis, said drum having a predetermined diameter and axial length, and further having first and second end walls, a cylindrical wall disposed between said first and second end walls, said cylindrical wall being constructed of a material which permits the passage of liquids and glasses therethrough, and at least one vane structure of a predetermined surface area disposed longitudinally on said enclosure cylindrical wall;   b) means to rotate said drum at a constant predetermined rotational velocity;   c) means to allow ingress of material into said drum, said ingress means being disposed in said first end wall;   d) an egress aperture disposed axially, with respect to said drum, in said second end wall;   e) a hollow cylindrical chute disposed in said egress aperture and having a first open end extending into said drum, and a second open end which is open to the exterior of said drum; and   f) means, disposed inside said housing structure, to emit a liquid agent into said drum, whereby post consumer plastic waste material is input through said ingress means to said drum and is mixed with said liquid agent, said mixture being subsequently output through said egress aperture, via said cylindrical chute.